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## Meet the editors

Dr. Swamini Chopra is an assistant professor at the Maharashtra Institute of Technology (MIT), India, working in materials engineering at the Center of Excellence in Materials and Metallurgy. She was formerly associated with the Defence Institute of Advanced Technology (DIAT), India, on a project sponsored by the Department of Science and Technology (DST), Government of India. Dr. Chopra has been recognized twice by the Cryo-

genic Society of America for her contributions to the field of cryogenics. She has more than thirty journal publications and three patents to her credit. She has also authored two books and edited two books on the topics of materials science, carbon-based nanomaterials, and cutting tools. She is actively associated with undergraduate, postgraduate, and Ph.D. scholars at her institute and her areas of interest include cryogenic treatment, polymer composites, applications of carbon-based materials, and mechanical performance of materials.

Dr. T. R. Vijayaram is a Senior Professor in the Department of Mechanical Engineering under the School of Mechanical Engineering, BIST, Bharath Institute of Higher Education and Research (BIHER), Selaiyur, Chennai, Tamil Nadu, India. He is an expert in the field of materials and metallurgical, manufacturing, and mechanical engineering. He received his B.E. degree in Mechanical Engineering from Madurai Kamaraj University,

followed by an M.E. degree in Industrial Metallurgy from PSG College of Technology, Bharathiyar University. He obtained his Ph.D. research degree in Mechanical Engineering from Universiti Putra Malaysia, Malaysia. Later, he worked as a Rector researcher in metallurgy at DCCI, Genoa University, Italy. His passion for academics, research, and education led him to obtain an MBA in Educational Management and an MA in Sociology from the University of Madras. He is also a Chartered Engineer (India) and a member of several professional and scientific bodies in India and abroad like ISTE (Life Member), IEI, IIF, and SAE (USA). He is also a Fellow of the Institution of Engineers, FIE, India. Recently, Dr. T. R. Vijayaram received the Distinguished Scientist Award in Metallurgical and Materials Engineering for his outstanding contribution to metallurgy. He has published more than 230 papers in international and national journals, conferences, broadsheets, and magazines. His areas of research include materials engineering, metallurgical engineering, manufacturing engineering, and mechanical engineering.

### Contents


Preface

In the ever-evolving realm of metallurgy, the pursuit of innovative methods and new perspectives is the crucible in which progress is forged. *Extraction Metallurgy – New Perspectives* represents a milestone in our collective journey to understand and harness the intricate processes that transform ores and minerals from the Earth into the materials that underpin our modern world. As the editor of this volume, I am both honored and excited to present a comprehensive exploration of the latest advancements and fresh insights in this dynamic field. Metallurgy, often described as the science and art of extracting metals from their ores and shaping them into useful forms, has a rich history dating back millennia. From the dawn of civilization to the present day, metallurgy has been instrumental in shaping human society, powering industrial revolutions, and fueling technological innovations. Yet, as we stand on the precipice of a new era marked by sustainability and resource consciousness, the traditional paradigms of metallurgy are being redefined. This book delves into the heart of modern extraction metallurgy, where traditional knowledge intersects with cutting-edge research. It covers a wide array of topics, from the fundamentals of ore characterization to the complexities of hydrometallurgical processes. It explores the environmental and economic aspects of mineral extraction and presents novel

approaches to reduce the environmental footprint of the industry.

to reflect on the broader implications of our metallurgical endeavors.

sible, and transformative metallurgy.

*Extraction Metallurgy – New Perspectives* embraces the interdisciplinary nature of modern metallurgy. Advances in materials science, chemistry, physics, and engineering converge in the pursuit of more efficient and environmentally responsible extraction processes. Researchers and practitioners from diverse fields have contributed their expertise to this volume, emphasizing the importance of collaboration in pushing the boundaries of metallurgical knowledge. Moreover, this book is not confined to the laboratory or industrial setting. It recognizes the global significance of mineral resources and the critical role they play in geopolitics and economic development. By examining the geopolitical dynamics of mineral extraction and the ethical considerations surrounding resource distribution, this book invites readers

In closing, I would like to express my profound gratitude to the contributors who have shared their insights, experiences, and expertise to make this book a reality. I extend my thanks to my colleagues, mentors, and the entire metallurgical community for their unwavering dedication to advancing our field. And I invite readers, whether seasoned professionals or curious novices, to embark on this journey through *Extraction Metallurgy – New Perspectives*, where tradition meets innovation and where the future of our industry is being shaped. May this volume serve as a source of inspiration, knowledge, and collaboration as we forge ahead in the pursuit of sustainable, respon-

## Preface

In the ever-evolving realm of metallurgy, the pursuit of innovative methods and new perspectives is the crucible in which progress is forged. *Extraction Metallurgy – New Perspectives* represents a milestone in our collective journey to understand and harness the intricate processes that transform ores and minerals from the Earth into the materials that underpin our modern world. As the editor of this volume, I am both honored and excited to present a comprehensive exploration of the latest advancements and fresh insights in this dynamic field. Metallurgy, often described as the science and art of extracting metals from their ores and shaping them into useful forms, has a rich history dating back millennia. From the dawn of civilization to the present day, metallurgy has been instrumental in shaping human society, powering industrial revolutions, and fueling technological innovations. Yet, as we stand on the precipice of a new era marked by sustainability and resource consciousness, the traditional paradigms of metallurgy are being redefined. This book delves into the heart of modern extraction metallurgy, where traditional knowledge intersects with cutting-edge research. It covers a wide array of topics, from the fundamentals of ore characterization to the complexities of hydrometallurgical processes. It explores the environmental and economic aspects of mineral extraction and presents novel approaches to reduce the environmental footprint of the industry.

*Extraction Metallurgy – New Perspectives* embraces the interdisciplinary nature of modern metallurgy. Advances in materials science, chemistry, physics, and engineering converge in the pursuit of more efficient and environmentally responsible extraction processes. Researchers and practitioners from diverse fields have contributed their expertise to this volume, emphasizing the importance of collaboration in pushing the boundaries of metallurgical knowledge. Moreover, this book is not confined to the laboratory or industrial setting. It recognizes the global significance of mineral resources and the critical role they play in geopolitics and economic development. By examining the geopolitical dynamics of mineral extraction and the ethical considerations surrounding resource distribution, this book invites readers to reflect on the broader implications of our metallurgical endeavors.

In closing, I would like to express my profound gratitude to the contributors who have shared their insights, experiences, and expertise to make this book a reality. I extend my thanks to my colleagues, mentors, and the entire metallurgical community for their unwavering dedication to advancing our field. And I invite readers, whether seasoned professionals or curious novices, to embark on this journey through *Extraction Metallurgy – New Perspectives*, where tradition meets innovation and where the future of our industry is being shaped. May this volume serve as a source of inspiration, knowledge, and collaboration as we forge ahead in the pursuit of sustainable, responsible, and transformative metallurgy.

#### **Swamini Chopra**

**1**

Section 1

Introduction

Center of Excellence in Materials and Metallurgy, Maharashtra Institute of Technology, Aurangabad (M.S.), India

#### **Thoguluva Vijayaram**

Senior Professor, Department of Mechanical Engineering, School of Mechanical Engineering, BIST, BIHER, Bharath Institute of Higher Education and Research, Selaiyur, Chennai, Tamil Nadu, India

Section 1 Introduction

#### **Chapter 1**

## Introductory Chapter: Extraction Metallurgy – New Perspectives

*Swamini Chopra*

#### **1. Introduction**

Metallurgy is the scientific field that deals with the study of metals and their properties. While extraction metallurgy is a branch of metallurgical engineering that focuses on the extraction of metals from ores, their refining techniques and converting them into useful materials. Extraction of useful metals is a vital aspect of metallurgy, and nowadays it is not only limited to metallic ores [1, 2]. The mining and refining of minerals like borosilicate and calcium carbonate for engineering applications is also considered a part of extraction science [3]. The extraction process involves a series of complex steps that require specialized knowledge, advanced technology, and highly skilled workers. Extraction metallurgy is critical to modern society, as it provides the raw materials for many industries, including aerospace, construction, energy, and electronics. This book brings together some of the recent developments in the field of extraction and refining of extracted products, followed by their applications. Meanwhile, this introductory chapter will provide an overview about extraction metallurgy, including its history, importance, and the main steps involved in the process. The chapter will also highlight some of the key challenges and research advances in extraction metallurgy, as well as some of the environmental and social impacts of the industry.

#### **1.1 History of extraction metallurgy**

The history of extraction metallurgy can be traced back thousands of years, to the early days of human civilization. The earliest metalworkers used simple techniques to extract metals from their ores, such as heating them in fires or washing them with water. Over time, as metallurgical knowledge and technology advanced, more complex methods were developed [4, 5].

One of the most important advances in extraction metallurgy occurred during the industrial revolution in the eighteenth and nineteenth centuries [6]. During this time, new technologies were developed that enabled large-scale production of metals such as iron and steel. The Bessemer process, invented in the 1850s, was one of the most significant advances in the field. This process involved blowing air through molten iron to remove impurities and produce high-quality steel [7, 8].

Since then, extraction metallurgy has continued to evolve and improve, with new technologies and methods being developed to extract a wider range of products and produce them more efficiently.

#### **2. Importance of extraction metallurgy**

The use of metals and minerals is an essential component of modern society. Metals are used in the construction of buildings, transportation systems, and consumer goods such as electronics and appliances [9]. Minerals are used in a wide range of industries, including agriculture, construction, and manufacturing [10, 11]. However, the raw materials for these products are not readily available in their usable forms. The ores that contain these metals and minerals are often found in remote locations and require extensive processing to extract the valuable metals and minerals.

Extraction metallurgy is the process of extracting metals and minerals from their ores. It is a critical process in the mining industry and plays an essential role in the production of many industrial and consumer goods [2]. The extraction of metals involves a series of steps that are designed to separate the desired metal from the rest of the ore. This process involves the use of various chemical, physical, and mechanical methods to separate the metal from the ore. Extraction metallurgy is an important process that has significant economic and environmental implications. The economic importance of extraction metallurgy is evident from the fact that it is used to extract valuable metals that are used in various industrial processes [12]. These metals include copper, gold, silver, lead, zinc, nickel, and iron. The value of these metals varies, but they are all in demand due to their unique properties and uses. For example, copper is one of the most widely used metals in the world and is used in electrical wiring, plumbing, and electronic devices. Iron is used in the construction of buildings, bridges, and vehicles. Zinc is used in galvanizing steel, and aluminum is used in the construction of airplanes, cars, and beverage cans. Extraction metallurgy has also played a critical role in the development of new technologies. For example, the extraction of lithium from brines has become essential for the production of lithiumion batteries [13, 14], which are used in electric vehicles and portable electronic devices. The extraction of rare earth elements from ores has also become increasingly important for the production of electronics and advanced technologies.

Extraction metallurgy also plays a crucial role in reducing the environmental impact of mining. Mining can have significant environmental consequences, including soil erosion, water pollution, and habitat destruction. By using extraction metallurgy to extract metals from ores, the environmental impact of mining can be reduced. This is because extraction metallurgy involves the use of various chemical and physical processes that allow for the efficient extraction of products from ores.

#### **3. Importance of research in extraction metallurgy**

Research in extraction metallurgy is important because it allows for the development of new and more efficient processes for extracting metals and minerals from ores. This is important because their demand is ever increasing, and traditional extraction processes may not be able to keep up with this demand. Research in extraction metallurgy also allows for the development of more environmentally friendly processes that reduce the impact of mining on the environment. For example, investigating the use of bioleaching to extract copper from its ore is proving to be an efficient process by using microorganisms to break down the sulfide minerals in copper ore [15, 16]. This process might prove to be more environmentally friendly than traditional smelting as it produces fewer emissions and requires less energy.

Research in extraction metallurgy also allows for the development of new materials and alloys that have unique properties and uses. In near future, the use of nanotechnology to develop new materials with unique properties will accelerate the future of metallurgy. These materials may have applications in various industries, including electronics, medicine, and energy.

#### **4. Challenges in extraction metallurgy**

Apart from the benefits, extraction metallurgy is a complex process that involves many challenges. One of the biggest challenges is the fact that ores are often complex mixtures of minerals that must be separated to extract the desired component [17, 18]. This requires the use of various chemical and physical processes that can be expensive and time-consuming. Another challenge in extraction metallurgy is the fact that ores may contain impurities that can interfere with the extraction process. For example, copper ore may contain sulfur, which can form sulfur dioxide during smelting [15]. This can lead to environmental problems such as acid rain.

#### **5. Extraction metallurgy process**

Irrespective of the metal or mineral to be extracted, the process of extraction remains fairly same. It involves steps like mining, crushing, grinding, concentration, smelting, refining, and casting. The choice of method for extraction depends on several factors such as the type of ore, the concentration of the metal or mineral within the ore, and the desired purity of the final product. These steps are discussed below:

• Mining

The first step in extraction is the mining. Mining involves the extraction of ores from the earth's crust. Ores are rocks that contain valuable metals such as copper, gold, silver, and platinum. The mining process involves drilling, blasting, and hauling the ore to the surface.

• Crushing and grinding

Once the ore is extracted, it is crushed and ground into small particles. This process increases the surface area of the ore, making it easier to extract the metal or mineral. The crushing and grinding process may involve several stages, depending on the size of the ore and the desired particle size.

• Concentration

After the ore is crushed and ground, it is concentrated to increase the concentration of the metal or mineral to be extracted. Concentration involves separating the desired material from the unwanted components present in the ore. This is typically done using gravity separation, flotation, or magnetic separation. Gravity separation involves using the differences in the density of the metal or mineral and the surrounding rock to separate them. Flotation involves using chemicals to make the metal or mineral hydrophobic, or repel water, and the surrounding rock hydrophilic, or attract water. Magnetic separation involves using magnets to separate the metal or mineral from the surrounding rock.

• Smelting

Smelting is the process of extracting metal from its ore by heating it to a high temperature in the presence of a reducing agent. The reducing agent reduces the metal oxide to metal. The most commonly used reducing agent is coke (a form of carbon). The metal is then separated from the slag (the waste material) using various techniques.

• Refining

After smelting, the metal is purified further to remove any impurities. This process is known as refining. This process is used for minerals as well and involves the use of various techniques such as electrolysis, precipitation, and distillation.

• Casting

The final step in metal extraction is casting. The purified metal is cast into various shapes and forms, depending on its intended use. Casting involves melting the metal and pouring it into a mold to give it the desired shape. This step is not usually needed for the minerals.

### **6. Extraction techniques**

The extraction of useful products can be achieved by following techniques [19, 20]:

• Hydrometallurgy

Hydrometallurgy is a metal extraction technique that involves the use of aqueous solutions to extract metals from their ores. In this technique, the metal is dissolved in an acidic or alkaline solution, and the impurities are separated using various methods.

• Pyrometallurgy

Pyrometallurgy is a metal extraction technique that involves the use of high temperatures to extract metals from their ores. In this technique, the ore is heated to high temperatures, and the metal is extracted using various methods.

• Electrometallurgy

Electrometallurgy is a metal extraction technique that involves the use of electricity to extract metals from their ores. In this technique, the metal ions in the ore are reduced to metal using an electric current.

*Introductory Chapter: Extraction Metallurgy – New Perspectives DOI: http://dx.doi.org/10.5772/intechopen.112882*

### **Author details**

Swamini Chopra Centre of Excellence in Materials and Metallurgy, Maharashtra Institute of Technology, Chhatrapati Sambhajinagar, Maharashtra, India

\*Address all correspondence to: chopra.swamini@gmail.com

© 2023 The Author(s). Licensee IntechOpen. This chapter is distributed under the terms of the Creative Commons Attribution License (http://creativecommons.org/licenses/by/3.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

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### Section 2
